Tubular sock module with integrated geogrid extensions for constructing stabilized-earth walls and slopes

ABSTRACT

A self-supporting earth facing module has a tubular sock to be filled with compost or fill material and a geogrid sheet which wraps around the circumference of the tubular sock with upper and lower extensions extending lengthwise to one side of the sock. The geogrid sheet is joined by a high-strength seam to the circumference of the sock. The module forms an integrated unit that can be used to form sequenced horizontal earth layers and serve as facing for a geosynthetically stabilized earth wall or slope. The sock may be vegetation-supportive and have built-in connectable irrigation tubing. The modules are installed in consecutive vertical lifts with a granular interlock zone to provide a connection medium for tying adjacent modules to each other and to the reinforced soil zone, and which may include connection to supplemental geogrids that extend the width of the reinforced zone for taller slopes and walls.

TECHNICAL FIELD

The present invention is directed to a self-supporting earth facing module and method for constructing mechanically stabilized earth walls and slopes using a fabric, tubular sock module filled with compost or fill material and having integrated geogrid extensions for reinforcement of a geosynthetically stabilized earth zone.

BACKGROUND OF INVENTION

Soil reinforcement with layers of man-made inclusions, such as steel strips, steel grids, geotextile fabrics, and polymeric geogrids, has been used by geotechnical engineers for the past 40 years. The use of planar, horizontal reinforcing elements in a compacted soil backfill allows for the construction of mechanically stabilized earth (MSE) structures that include steepened slopes (known as reinforced soil slopes, or RSS) and near-vertical walls. FIG. 1 illustrates examples: of (1) vertical geosynthetic facing; (2) sloping geosynthetic facing; (3) sloping gunite or structural facing; (4) vertical precast concrete element facing; (5) sloping soil and vegetation facing; (6) geosynthetic gabion; (7) vertical cast in-place concrete/masonry facing; and (8) vertical modular block wall (MBW) facing. Reference is made to U.S. Dept. of Transportation, Publ. No. FHWA-NHI-00-043, p. 49, 2001. Near-vertical walls where the reinforcing elements are connected to modular units that serve as the wall facing are illustrated, for example, in U.S. Pat. No. 3,686,873 to Vidal.

Large precast concrete panels and smaller modular block dry-cast concrete units are the most common hard facing units (examples (4) and (8) shown in FIG. 1). In the latter case, the constructed walls are known as modular block walls (MBW) or segmental retaining walls (SRW). The stacked facing units are connected with proprietary interlocking systems such as shear pins, lips, tongue-and-groove, or clips as illustrated, for example, in U.S. Pat. No. D295,788 to Forsberg, U.S. Pat. No. 4,909,010 to Gravier, U.S. Pat. No. 4,920,712 to Dean, Jr., and U.S. Pat. No. 6,322,291 to Rainey.

Wall facings also can be comprised of welded wire panels or gabions (wire baskets filled with stones) connected to grid reinforcement elements in the backfill zone. Wrapped geosynthetic faced MSE walls and slopes also can be constructed, but they require temporary bracing (falsework) at the face to support the soil being compacted immediately behind the geosynthetic facing, as illustrated in the steps depicted in FIG. 2. Reference is made to U.S. Dept. of Transportation, Publ. No. FHWA-NHI-00-043, p. 47, 2001. These often require a secondary, more permanent facing treatment, such as sprayed-on shotcrete or gunite on near-vertical faces and special seeding and erosion control treatments for reinforced slopes. Construction of a wrapped geosynthetic MSE structure consists of the consecutive lift sequences of: (1) compacting a lift of backfill soil, then installing a temporary face form (falsework) on the top of that lift, then laying the next horizontal geosynthetic on the backfill and hanging it over the falsework; (2) compaction of the next backfill lift, then wrapping of the geosynthetic back over the lift; (3) placing and compacting the remainder of the backfill lift over the wrap end. The falsework needs to be removed prior to repeating the entire process for the next lift.

In recent years, tubular geofabric socks filled with soil, growing media, organic fibers, and/or compost have been available commercially for various applications in erosion and sediment control. For example, the FilterSoxx™ tubular sock product is commercially available from Filtrexx International, LCC, of Grafton, Ohio, and another product known as the BioSock™ system is commercially available from EnviroTech BioSolutions, Inc., of Honolulu, Hi. These types of socks can be used as wall or slope facings when wrapped with geosynthetic layers to construct the MSE structures. The combination of the tubular sock facing with geosynthetic layers can provide a wrapped, erosion-preventive surface treatment that contains a growth medium for vegetation that can be seeded or sprigged to form a vegetated slope facing. However, the combined structures require a wrapped geosynthetic protocol to tie the socks to the reinforcing layers in the backfill in order to stabilize them in position. They can eliminate the need of temporary forms or falsework, but still require using cable anchors, steel rods, or wooden stakes to anchor each lift of sock to the slope face.

Thus, regardless of the type of materials or construction method used conventionally for wrapped geosynthetic MSE structures, the soil-compaction process in the reinforced backfill zone near the final slope face requires that the face (or facing elements) be supported with temporary bracing (falsework) or by using cable anchors or stakes. In addition, these wrapped MSE structures are limited to linear alignments due to the manner in which the geosynthetic fabric is wrapped back over itself with each backfill lift. It would be highly desirable to provide a self-supporting facing module and method of installing each lift of a mechanically stabilized earth (MSE) structure without the need for supporting each lift with temporary bracing (falsework) or by using cable anchors or stakes.

SUMMARY OF INVENTION

In accordance with the present invention, a self-supporting earth facing module comprises: (a) a tubular sock made of a specified fabric material having a hollow interior volume which is to be filled with a compost or fill material so as to form a semi-rigid sock facing of a given sock diameter and a given sock length extending in a widthwise direction of the module; and (b) a geogrid sheet made of a geosynthetic sheet material and having a sheet width in the widthwise direction of the module and a sheet length sufficient to extend around the circumference of the tubular sock with upper and lower extensions of given extension lengths extending in a lengthwise direction of the module to one side of the tubular sock, wherein the sheet material of said geogrid sheet is joined by a high-strength seam to the sock material of the tubular sock at a juncture point where at least the lower extension of the geogrid sheet adjoins a circumferential point of the tubular sock, whereby said module forms an integrated unit that can be used to form a sequenced horizontal earth layer of a plurality of layers and serve as facing for a geosynthetically stabilized earth wall or slope.

In a preferred embodiment, the tubular sock containing the compost or fill material has a double layer of two different high-strength fabrics that combine to form a strong containment system for the infill. An inner fabric is a porous nonwoven material that has small enough openings to contain organic fines, yet is coarse enough to allow germinated seedlings to grow through the material. An outer fabric is a high-strength netting that provides tensile constraint to maintain module roundness as the compost or fill material is tightly packed into the sock to form a dense infilling.

The geogrid sheet is preferably a single, rectangular piece with biaxial tensile strength and with a width approximately equal to the length of the assembled tubular module. The overall sheet length may typically be equal to about 10 to 15 times the diameter of the sock. The geogrid material is centered and sewn to one hemispherical side of the sock such that the free extension ends of the geogrid sheet extend in the lengthwise direction at the top and bottom of the tubular sock as it lies horizontal. The hemispherical side of the sock wrapped with the geogrid sheet serves as the outward facing for the earth layer filled using the modular unit. The extension ends of geogrid sheet extend along the top and bottom of the earth layer into the reinforced soil zone behind the facing.

This new technology provides an engineered and erosion-preventive facing that can be pre-seeded within the compost or fill material prior to installation, hydroseeded after installation, and/or sprigged with live cuttings of plants in-between consecutive layers of the facing modules during installation.

The modular sock is preferably manufactured such that the sewing of the geogrid sheet to the sock wall is accomplished to ensure that the wide-width tensile strength of the stitched seam exceeds the wide-width tensile strength of the geogrid sheet itself. Thus, if an installed module were to experience an over-stressed condition, the geogrid extensions and/or hemispherical wrap would rupture before the seam would break, meaning that the known design strength of the geogrid sheet serves as the critical element in the geotechnical design analysis for the MSE structure.

The construction of an MSE earth wall or slope involves installation of a plurality of the self-supporting earth facing module units in successive horizontal lifts, with each lift comprised of modular units installed by butting them end-to-end, wherein the top and bottom geogrid extensions of adjacent modules are locked into the backfill zone in horizontal soil layers compacted to density specifications from the design engineer. To assure optimal interlock between the backfill and the geogrid sheets, the backfill material shall preferably consist of granular, well-graded sand or sandy gravel with less than 15 percent by weight passing the No. 200 sieve, and with a maximum particle size of 0.75 inch (19 mm). The extension length of this granular interlock zone behind the facing modules is preferably at least twice the diameter of the tubular sock modules.

Other objects, features, and advantages of the present invention will be explained in the following detailed description of the invention having reference to the appended drawings.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 illustrates various types of facing used for mechanically stabilized earth (MSE) walls and slopes in the prior art.

FIG. 2 illustrates a lift construction sequence in the prior art for geosynthetic-faced MSE walls.

FIG. 3 shows a schematic sectional view of a self-supporting earth facing module in accordance with the present invention.

FIG. 4 shows a preferred type of tubular sock with built-in connectable irrigation system for use with the self-supporting earth facing module.

FIGS. 5A and 5B illustrate respectively the male/female connection ends of the preferred type of tubular sock for use with the self-supporting earth facing module.

FIG. 6 illustrates the construction sequence for an MSE structure using module units.

FIG. 7 illustrates the active and resistant zones within a geogrid-reinforced zone.

FIG. 8 illustrates an example of a completed wall section using the tubular sock modules.

FIGS. 9A, 9B, and 9C show plan views of forming straight, concave and convex facings in wall alignment by aligning, overlapping, or spreading extension ends in the granular interlock zone.

FIG. 10 Illustrates how taller MSE structures can be constructed using a wider reinforced-soil zone.

DETAILED DESCRIPTION

In the following detailed description of the invention, certain preferred embodiments are illustrated providing certain specific details of their implementation. However, it will be recognized by one skilled in the art that many other variations and modifications may be made given the disclosed principles of the invention.

Referring to FIG. 3, a self-supporting earth facing module is formed with a tubular sock made of a specified fabric material having a hollow interior volume which is to be filled with a compost or fill material so as to form a semi-rigid sock facing of a given sock diameter SD and sock length SL (extending in a widthwise direction of the module). A geogrid sheet made of a geosynthetic sheet material and having a sheet width GW (in the widthwise direction of the module) and a sheet length GL sufficient to extend around the circumference of the tubular sock with upper and lower extensions of given extension lengths EL extending in a lengthwise direction of the module to one side of the tubular sock. The sheet material of the geogrid sheet is joined by a high-strength seam to the sock material of the tubular sock at a juncture point where at least the lower extension of the geogrid sheet adjoins a circumferential point of the tubular sock. In a preferred embodiment, both upper and lower seams are used to join the geogrid sheet to upper and lower points on the circumference of the sock.

The compost or fill material used in the tubular sock modules may consist of various materials or mixtures of materials, such as: a) compost derived from green waste or other organic materials, such as grass clippings, chipped tree branches, shredded wood, shredded brush and other plant debris, chipped bark, wood sawdust and shavings, peat moss, hay or straw, seed hulls, rice hulls, manure, poultry dung, sea-bird or bat guano, and sea kelp; b) soil mixtures with or without organic constituents, such as loam, silt, sand, gravel, crushed aggregate, crushed coral, gypsum, lime, dolomite, oyster shell, vermiculite, perlite, cinder, pumice; c) plant and animal fibers, such as virgin cellulose fiber, coir, bagasse, corn fiber, flax fiber, cotton fiber, hemp fiber, wool fiber, and hair; d) synthetic materials such as recycled plastic, recycled glass, recycled paper and cardboard, recycled foam, plastic beads, Styrofoam, synthetic fibers, and polymers; e) nutrients, soil amendments and fertilizers, such as fish emulsion, flax seed oil, enzymes, soil bacteria and microorganisms, fungi, bio-stimulants, microbial inoculants, worm castings, bone meal, feather meal, humate, humic acid, organic fertilizers, synthetic fertilizers, and nutrient-rich plant food; and f) plant seeds and live cuttings, such as live seed and roots, spores, vines, sprigs, stolons, and rhizomes.

In a preferred embodiment, the tubular sock containing the compost or fill material has a double layer of two different high-strength, geosynthetic fabrics that combine to form a strong containment system for the infill. An outer fabric S1 is a high-strength netting that provides tensile constraint to maintain module roundness as the compost or fill material is tightly packed into the sock to form a dense infilling. An inner fabric S2 is a porous nonwoven material that has small enough openings to contain organic fines, yet is coarse enough to allow germinated seedlings to grow through the material.

The geogrid sheet is preferably a single, rectangular piece with biaxial tensile strength and with a width approximately equal to the length of the assembled tubular module. The overall sheet length may typically be equal to about 10 to 15 times the diameter of the sock. The geogrid material is centered and sewn to at least one hemispherical side of the sock such that the free extension ends to of the geogrid sheet extend in the lengthwise direction at the top and bottom of the tubular sock as it lies horizontal. The hemispherical side of the sock wrapped with the geogrid sheet serves as the outward facing for the earth layer filled using the modular unit. The extension ends of the geogrid sheet extend on the top and bottom of the earth layer into the reinforced soil zone behind the facing.

The modular sock is preferably manufactured such that the sewing of the geogrid sheet to the sock wall is accomplished to ensure that the wide-width tensile strength of the stitched seam exceeds the wide-width tensile strength of the geogrid sheet itself. Thus, if an installed module were to experience an over-stressed condition, the geogrid extensions and/or hemispherical wrap would rupture before the seam would break, meaning that the known design strength of the geogrid sheet serves as the critical element in the geotechnical design analysis for the MSE structure.

The tubular sock is preferably of the type that is in modular sock units with built-in irrigation tubing that can be connected serially end-to-end so that a long continuous row of facing can be formed in each horizontal earth layer, such as the product known as the Wiki-Garden™ system, commercially available from EnviroTech BioSolutions, Inc., of Honolulu, Hi. The modular sock units each have a pre-determined modular length and can be pre-filled with growing media for plants therein. A plastic/nylon irrigation tube is installed lengthwise through the growing sock with opposite ends thereof projecting through apertures formed in the sock material, wherein a male coupling fitting is attached to one end of the tube and a female coupling fitting to the opposite end. A plurality of tubular sock module sections can be coupled together in series with each section having its male and female coupling fitting attached to an opposite coupling fitting of an adjoining section.

Referring to FIG. 4, each modular sock section 10 is comprised of a pre-determined length SL of a porous tubular sock made of a mesh or netting material that is pre-filled with growing medium for plants therein. The length SL can be any length convenient for fabrication, filling, distributing, transport, storage, and installation. For example, the length SL between tied-off ends 11 of the sock can be 3 to 5 feet in length, which is convenient for handling and stacking on a pallet, and for computing lengths needed for the wall facing. The modular sections are filled by the manufacturer using a bark blower, auger machine, high-speed conveyor machine, gravity chute, or manual means. As part of the manufacturing process, a modular length of irrigation tube 12 is installed through the sock having a length matching the length SL of the sock between its male end 12 a and female end 12 b.

FIG. 5A shows a sectional view of the male end 12 a of the growing sock. The end of the irrigation tube 12 is press-fitted into a receiving end 14 of a male coupling fitting 12 a and retained tightly therein by a retention ring 14 a with a sharp edge that presses into the surface of the tube 12 and grips it tightly. The outside facing surface 14 b of the retention ring has a greater diameter than that of the tube 12 and presents an inclined flange or shoulder that abuts the outer surface of the growing sock 10 to prevent it from slipping or sliding longitudinally along the tube 12. The other, connecting end 15 of the male coupling fitting 12 a has a threaded outer surface 15 a for threading into a female socket of an adjoining modular section, or an end cap 16 as shown in the drawing. An O-ring 17 may be installed on the male threaded end for sealing in the female socket or end cap.

The modular length of tube 12 has a number of emitter holes 12 c distributed over its length. The number of emitter holes and their orifice size are designed to deliver a pre-determined volume of water by drip irrigation into the length of the growing sock. As described in detail below, the pre-determined volume of water delivered by each modular section is selected to facilitate easy computation of the number and types of sections that can be coupled together in a series for a water source of given water pressure and water delivery volume. For example, for a tube of 3-foot length the same as the growing sock, there may be 3 emitter orifices spaced from 8″ up to 18″ apart.

FIG. 5B shows a sectional view of the complementary female end 12 b of the growing sock. The end of the irrigation tube 12 is press-fitted into a receiving end 18 of a female coupling fitting 12 b and retained tightly therein by a sharp retention ring 18 a. The outside facing surface 18 b of the retention ring has a greater diameter than that of the tube 12 and presents an inclined flange which, along with the flange 14 b of the male coupling fitting 14 on the opposite side of the growing sock 10, locks the growing sock in position to prevent it from slipping or sliding longitudinally along the tube 12. The other, connecting end 19 of the female coupling fitting 12 b can be a swivel hose coupling with a threaded inner surface 19 a for threading in a male end of an adjoining modular section. An O-ring 20 may be installed in the female threaded end for sealing.

For a more detailed description of this modular sock system, reference is made to U.S. patent application Ser. No. 12/604,132, of Alan Joaquin (who is a co-inventor herein), filed Oct. 22, 2009, entitled Modular Tubular-Sock Garden Growing System, which is incorporated by reference herein.

Construction of a MSE wall or slope using the tubular sock modules and soil-reinforced zone provides a coherent gravity mass to resist overturning and sliding forces that result from the active earth pressure applied by the retained soil in the slope. The system relies on the synergy between the facing module, its attached geogrid extensions, and the granular interlock zone. This interlock zone, wherein the modules are connected to each other and to the reinforced soil backfill, is adjacent to the back of the modules and typically has a width of at least two times the diameter of the tubular facing modules.

Referring to FIG. 6, construction of a stabilized earth wall using the tubular sock modules in conjunction with a compacted granular interlock zone and using a running bond along the rows of modules is illustrated. Construction proceeds in the following steps:

(1) Prepare and compact a gravel leveling pad to receive the first row of sock modules. Lay first row of modules end-to-end along the prescribed wall alignment, with the lower geogrid extension on each module pulled out flat on top of the gravel pad, and with the upper geogrid extension laid loosely back over the module in the opposite direction. Where the tied-off end of each module (that is, the tied-off end of the sock that results from filling the sock with compost or fill material) butts against the end of the adjacent module, the excess geogrid flap (approximately 5 inches wide, which results from cutting the geogrid as required to tie-off the sock after filling) is overlapped onto the lower geogrid of the adjacent module after spreading a thin layer of granular fill onto that lower geogrid. This layer of granular fill prevents the two geogrids from being in direct contact with each other, which could form a weak shear surface.

(2) After all modules are laid for a given row, granular backfill is placed carefully on top of the lower geogrid extensions of the modules to provide a lift as high as the module height, with special care taken to place the granular material against the lower portion of each module so as to eliminate any voids that could develop underneath the lower curved section of the module. On-site soil can be used in the reinforced zone behind the granular interlock zone, provided the soil is approved by the design engineer. The lift of backfill material is compacted within the reinforced zone according to density specifications from the design engineer. The integrated geosynthetic design of the modules allows mechanical compaction of the granular interlock zone immediately adjacent to the modules without the use of temporary bracing (falsework) and without the use of cable anchors or stakes to restrain the modules at the wall face.

(3) The upper geogrid extensions of the modules then are pulled back over the modules and laid out flat on top of the compacted backfill lift, then a thin layer of granular fill is spread across the top of the geogrid.

(4) The next vertical row (lift) of modules is placed slightly behind the modules below to provide a set-back in the wall face, and then is installed according to the previous Steps. Live vegetation in the form of sprigs or live cuttings can be inserted between lifts if desired. Also, if gentle curves are desired in the wall face, the geogrid extensions can be cut perpendicular to the axis of the tubular modules to allow spreading of the geogrid for concave wall faces and to allow geogrid overlapping for convex wall faces.

(5) In similar manner, these Steps are repeated for each successive vertical lift until reaching the final wall height as specified by the design engineer. If the compost or fill material in the modules did not include plant seeds, then the face of the wall is hydroseeded to establish a permanent, vegetated MSE wall or slope.

The granular interlock zone provides two other important features. First, it provides a free-draining zone to allow ground water to flow easily out of the backfill zone, thus preventing the buildup of any de-stabilizing effects due to pore-water pressure. Second, the high shear strength of this densely compacted granular zone, which typical will have friction angles in the range of 34° to 44°, results in a strong, coherent gravity mass near the slope face, which steepens the angle of the estimated maximum stress line and thus reduces the width of the active zone in front of that stress line and allows the longest possible embedment lengths for the geogrid extensions in the resistant zone behind that stress line.

FIG. 7 illustrates active and resistant zones within a geogrid-reinforced zone. Influence on the orientation of the potential failure surface is attributed to the friction angle (φ) of the backfill soil. The higher friction angle generates a steeper line, thus increasing the geogrid embedment length in the resistant zone.

FIG. 8 illustrates an example of a completed wall section using the tubular compost-filled sock modules for mechanically stabilized earth (MSE) structures for heights up to several meters. The sock modules are pre-seeded or hydroseeded to foam a vegetated, living wall at the facing.

Unlike traditional, wrapped geosynthetic MSE walls and slopes, the tubular sock modules can be installed to form gentle curves in the wall face, in that the geogrid extensions can be cut perpendicular to the axis of the tubular modules to allow spreading of the geogrid for concave wall faces and to allow geogrid overlapping for convex wall faces. FIGS. 9A, 9B, and 9C illustrate, respectively, a straight section, a convex outer radius section (geogrid extensions are cut to allow interior overlap), and a concave inner radius section (geogrid extensions are cut to allow interior spread). The geogrid extensions are overlapped several inches at the edges to “tie” the units together end-to-end.

In areas where consecutive geogrid layers directly overlap each other, they must be separated by a thin layer of granular material to assure solid interlock of the geogrid with the backfill and to prevent the possibility of a weak shear plane being formed between two vertically adjacent geogrid layers. Consecutive vertical lifts of the tubular modules should be laid in a running bond manner, so that the end-butt joint of two modules does not directly overlie an end-butt joint of modules below. This prevents the development of potentially weak vertical discontinuities up the face and within the geogrid-reinforced zone, which is critical for both curved and straight MSE walls and slopes.

The geogrid extensions on the tubular sock module can be any length that is appropriate, reasonable, and practical in regard to the manufacturing and production process, provided that length is not less than 3 feet (1 meter). This minimum length is based on recommendations from industry and government sources, which generally agree that a one-meter embedment length is adequate to engage the full wide-width tensile strength of most geogrid for most soils used in MSE wall backfills (for example, refer to the USDOT Publ. No. FHWA-NHI-00-043 and the NCMA 2009 Design Manual). The minimum embedment length required to engage the full wide-width tensile strength of a geogrid is known as the critical embedment length, and it is estimated as follows:

Le _(crit) =Fg _(stren)/[2dγC _(i) tan(φ)]

where:

-   -   Le_(crit)=minimum embedment length, in feet (or meters);     -   Fg_(stren)=wide-width tensile strength of the geogrid, usually         taken as the long-term design strength (LTDS) of the geogrid, in         pounds/foot (or kilonewtons/meter);     -   d=depth to the geogrid layer from the ground surface, in feet         (or meters);     -   γ=total unit weight of the backfill soil, in pounds/cubic foot         (or kilonewtons/cubic meter;     -   φ=friction angle of the geogrid-reinforced soil, in degrees;     -   C_(i)=unitless coefficient of interaction between backfill soil         and geogrid, with typical values of 0.75 for fine soils (silts         and clays), 0.85 for sands and silty sands, and 0.90 for gravels         and coarse sands.

As an example, for geogrids at the bottom and midway locations in the stabilized earth structure shown in FIG. 8, the estimated values of critical embedment length can be calculated as:

Le _(crit)=(12.7 kN/m)/(2·2 m·21.4 kN/m³·0.90·tan(38°)=0.21 m (0.7 ft), and

Le _(crit)=(12.7 kN/m)/(2·1 m·21.4 kN/m³·0.90·tan(38°)=0.42 m (1.4 ft), respectively,

assuming a typical sand/gravel unit weight of 21.4 kN/m³ (136 lb/ft³) and a geogrid long-term design strength (LTDS) of 12.7 kN/m (870 lb/ft). Thus, the one-meter long geogrid extensions, in conjunction with the granular interlock zone, provide adequate embedment in the resistant zone of the lower half of the structure where lateral earth pressures are the greatest.

The geogrid extensions can be made longer for applications in stabilized-earth walls and slopes taller than that shown in FIG. 8. For example, assuming a flat backslope behind the wall and no surcharge loads, the required length and LTDS of geogrid extensions to provide adequate internal stability of an MSE wall constructed at a face angle of 1:4 (Horz:Vert) could be based on the following schedule for typical tubular modules (with installed nominal diameter of 8 inches):

Length Min. of Module Maximum Wall Ht. Required φGranular Geogrid (No. of LTDS φBackfill Zone Extensions (ft) Rows) (ft) (lb/ft) 26° 26° 3.0 9 6.0 343 26° 26° 4.0 12 8.0 471 26° 26° 5.0 15 10.0 600 26° 26° 6.0 17 11.3 685 26° 32° 3.0 12 8.0 471 26° 32° 4.0 15 10.0 600 26° 32° 5.0 19 12.6 771 26° 32° 6.0 22 14.6 900 26° 38° 3.0 14 9.3 557 26° 38° 4.0 19 12.6 771 26° 38° 5.0 23 15.3 942 26° 38° 6.0 27 18.0 1113

In certain applications, the facing module units can be combined with supplemental geogrids to build tall composite, reinforced structures like that shown in FIG. 10. A large stabilized-earth structure is formed using supplemental geogrids with optional chimney drain and fence-post hole socket (facing is pre-seeded or hydroseeded to form a vegetated, living wall). In this case, geogrid-extension lengths of at least one meter on the modules allows for a reliable connection, primarily within the granular interlock zone, between the supplemental geogrids and the facing modules. The supplemental geogrids, which often will be spaced vertically at maximum intervals of 16 inches (0.4 meters), will butt up against the back of the facing modules and be sandwiched between the upper and lower geogrid extensions of vertically adjacent modular units. Because the geogrids directly overlap each other, they must be separated by a thin layer of granular material to assure solid interlock of the geogrids with the backfill and with each other.

Other unique advantages and alternative applications of this tubular sock module include the ability to use an infilling material partly composed of sand or gravel to allow the first several rows of facing modules to be installed at or below seasonal water levels along shorelines and stream banks; the ability to easily install post-hole socket pipes or sleeves in the uppermost three compaction lifts of a stabilized-earth wall or slope by using pre-cut holes in the integrated geogrid extensions on the modules and then slipping the geogrids vertically down over the sleeve (FIG. 10), which is not possible with a wrapped geosynthetic facing system; and the ability to include a built-in, flow-regulated, drip-irrigation system within the tubular sock modules.

Stabilized-earth structures built with these tubular sock modules do no require any special construction equipment (bracing forms, falsework panels) or additional add-on pieces such as anchor cables or stakes. They are self-contained units that, when properly placed in conjunction with a compacted backfill zone, provide a durable, green wall that can be installed by anyone with basic construction know-how and skill.

Example 1 High-Performance Materials for Durable Applications

In most applications it would be advantageous to construct the geogrid extensions out of a high-performance geogrid material, which typically consists of high-tenacity knitted polyester yarns with high molecular weight and covered with a polymeric coating to provide excellent durability and engineering properties. Such geosynthetic materials are mechanically and chemically durable to resist both the harsh construction installation phase and long-term contact with aggressive soil environments (pH range from 3-9). For example, a prime candidate for these geogrid extensions on the modules would be Stratagrid® Microgrid™ manufactured by Strata Systems, Inc., which has the following properties/specifications:

Ultimate biaxial tensile strength (ASTM D 6637): 2,000 lb/ft

Creep limited strength (ASTM D 5262 and D 6992): 1,149 lb/ft

Long-term design strength (LTDS): 871 lb/ft

Minimum molecular weight (GRI GG8): 25,000 g/mol

Maximum carboxyl end group count (GRI GG7): 30 meq/kg

Examples of other potential geogrid types for use as module geogrid extensions include Raugrid™ 2/2-20 biaxial geogrid (product of Carthage Mills), Mirafi® BXG biaxial geogrids, and TenCate Miramesh® SG geogrid (products of Koninklijke Ten Cate nv), the latter of which includes a synthetic grass component integrated with the geogrid sheet.

In applications that require durability it would be advantageous to construct the tubular sock portion of the module out of a synthetic fiber material that resists degradation, such as the BioSock Pro™ sock manufactured by EnviroTech BioSolutions, Inc. This sock is fabricated from polyester material and has the following properties/specifications:

150 Denier per filament

Fabric weight (ASTM D 3776): 3.5 oz/yd²

Puncture resistance (ASTM D 4833): 35

Diaphragm bursting strength (ASTM D 3786): 100 psi

Water permittivity (ASTM D 4491): 2.4 s⁻¹

Water flow rate at 3-inches head (ASTM D 4491): 300 gal/ft²/min

Apparent opening size, AOS (ASTM D 4751): U.S. sieve size 30

UV degradation strength retention after 300 hr (ASTM D 4355) 70 percent

The thread used to stitch the tubular sock module and attach the geogrid extensions could be TENARA® Sewing Thread as manufactured by GORE™ and would resist degradation from water, ultraviolet light, salt water exposure, and other outdoor elements. This adjoining of the sock to the geogrid shall be accomplished using a double-stitched seam, with a resultant wide-width tensile strength that shall exceed the wide-width tensile strength of the geogrid. If a large-aperture geogrid is used for the module extensions, then a high-strength backing tape shall be used for stitching the seam.

In certain applications it would be advantageous to treat the tubular, compost-filled fabric sock modules, including the attached geogrid extensions, with a fire retardant treatment. This would prove especially valuable for applications where the geosynthetic module system can be substituted for competing technology that is inherently flame resistant, such as concrete segmental retaining walls, especially when said applications are located in areas prone to the threat of wildfires.

Example 2 Biodegradable Materials for Environmentally Sensitive Applications

In certain applications it would be advantageous to construct the tubular sock portion of the module out of natural and biodegradable fabric material, such as a coir blanket woven from coir twines made of bristle coir obtained from freshwater cured coconut husks. For example, the Bio-D Mat® manufactured by Rolanka International, Inc., is comprised of such coir twines that have been machine spun to a uniform diameter. This coir blanket has the following properties/specifications:

Fabric weight (ASTM D 3776): 29 oz/yd² Dry tensile strength (ASTM D 4595) Machine direction 2024 lb/ft Cross direction 1160 lb/ft Wet tensile strength (ASTM D 4595) Machine direction 1776 lb/ft Cross direction 936 lb/ft Thickness (ASTM D 1777) 0.35 in. Open area 38 percent

Using the aforementioned materials to construct the tubular sock module would result in the geogrid extensions being synthetic and the sock structure being natural and biodegradable. The geogrid extensions would resist degradation and would be classified as “permanent” according to industry standards, such as the Erosion Control Technology Council guidelines for permanent turf reinforcement mats. The tubular sock structure itself would slowly and naturally biodegrade, yet the geogrid extensions would endure to act as reinforcement for the backfill soils and for the vegetative root zones of plants established on top and within the tubular sock module. Therefore, in ecologically sensitive applications, such as installation along a particularly critical body of water, the modules can be installed without the risk of synthetic fibers degrading and migrating into the aquatic habitat, which may pose health risks to biota, fish, and wildlife.

Example 3 Vegetative Facing Wall

The tubular sock module can be filled with an aggregate, such as crushed rock or coral, or a blend of aggregate and growing medium such as compost or a soil/compost mixture. The specific infill mix selected for filling the tubular sock module would be based on job-specific criteria. In certain applications it would be advantageous to fill the sock module with a pre-seeded and pre-fertilized growing medium. The growing medium could consist of organic compost with the following properties:

Range of pH 5.0-8.5 Stability (carbon dioxide rate) <8 Organic matter content (dry-weight basis) 25-65 percent Moisture content (wet-weight basis) 30-60 percent Soluble salt concentration (electrical conductivity) ≦5 dS/m Physical contaminants, manmade inerts (dry-weight <1 percent basis) Maximum particle length of 6 in., with a size distribution of Passing 3-in. sieve 100 percent Passing 1-in. sieve 90-100 percent Passing 0.75-in. sieve 70-100 percent Passing 0.25-in. sieve 25-65 percent

The fertilizer blended into the growing medium could be derived from dried poultry waste with a nutrient analysis of 4% nitrogen (1.25% water-soluble organic nitrogen and 2.75% water-insoluble organic nitrogen), 3% available phosphate, 3% soluble potash, and 7% calcium. The seeds blended into the growing media could consist of locally specified species of annual or perennial grasses, herbs, or low-growing shrubs.

The tubular sock module system can be filled with growing media on-site using manual means, such as shovels and/or gravity feed chutes. To increase speed and efficiency the tubular sock module could be filled with growing media using a pneumatic blower machine such as a FINNS Bark Blower® or an auger extrusion machine, such as the BioSolutions™ SE1000™. In certain applications, such as long continuous module installations, the tubular sock module could be filled with a high-speed conveyor belt feeding system, such as the AT7 manufactured by Conveyor Application Systems, LLC.

To promote healthy and vigorous growth, care must be taken to install pre-seeded and pre-fertilized modules on the slope face before the seeds begin germinating within the filled tubular sock. If adequate time and/or weather conditions prevent the modules from being installed within a suitable time frame, the tubular sock modules should be filled absent the seeds and fertilizer. The omitted seeds and fertilizer can be applied in the field after module installation by means of hydraulic planting using commercially available hydroseeding equipment, such as FINN® Hydroseeders®. The hydraulic planting operation would place the desired seeds and fertilizer onto the exposed face of the modules, thereby allowing the seeds to germinate and send roots through the geogrid and sock materials and into the encapsulated growing media, whereby said roots would mature and occupy the confines of the encapsulated growing media. A variety of commercially available hydraulic planting products can be used to manipulate the performance characteristics of the hydraulic planting installation, such as bonding strength, functional longevity, elasticity, moisture retention, and organic content. Some of the classifications and/or types of commercially available hydraulic planting products that are suitable for use with the module system are bonded fiber matrices (BFM), stabilized fiber matrices (SFM), flexible growth media (FGM), hydraulic growing media (HGM), cementitious binders, and organic mulches comprised of paper fiber, cellulous fiber, straw fiber, corn fiber, coconut fiber, hemp fiber, or wood fiber.

It is to be understood that many modifications and variations may be devised given the above description of the general principles of the invention. It is intended that all such modifications and variations be considered as within the spirit and scope of this invention, as defined in the following claims. 

1. A self-supporting earth facing module comprising: (a) a tubular sock made of a selected fabric material having a hollow interior volume which is to be filled with a compost or fill material so as to form a semi-rigid sock facing of a given sock diameter and a given sock length extending in a widthwise direction of the module; and (b) a geogrid sheet made of a geosynthetic sheet material and having a sheet width in the widthwise direction of the module and a sheet length sufficient to extend around the circumference of the tubular sock with upper and lower extensions of given extension lengths extending in a lengthwise direction of the module to one side of the tubular sock, wherein the geogrid sheet material is joined by a high-strength seam to the fabric material of the tubular sock at a juncture point where at least the lower extension of the geogrid sheet adjoins a circumferential point of the tubular sock, whereby said module forms an integrated unit that can be used to form a sequenced horizontal earth layer of a plurality of layers and serve as facing for a geosynthetically stabilized earth wall or slope.
 2. A self-supporting earth facing module according to claim 1, adapted for forming a vegetative facing wall, wherein the tubular sock is formed with two different high-strength fabrics for containing organic infill, including an inner fabric of a porous nonwoven material with small pore openings to contain organic fines but coarse enough to allow germinated seedlings to grow through the material, and an outer fabric of high-strength netting that provides tensile constraint to contain compost or fill material tightly packed into the sock to form a dense infilling.
 3. A self-supporting earth facing module according to claim 1, wherein the sheet material of said geogrid sheet is joined by upper and lower high-strength seams to the sock material of the tubular sock at upper and lower juncture points where the upper and lower extensions of the geogrid sheet adjoin circumferential points of the tubular sock, respectively.
 4. A self-supporting earth facing module according to claim 1, wherein the sheet material of said geogrid sheet is joined to the sock using a double-stitched seam, with a resultant wide-width tensile strength that exceeds the wide-width tensile strength of the geogrid sheet.
 5. A self-supporting earth facing module according to claim 4, wherein the sheet material is a large-aperture geogrid material, and a high-strength backing tape is used for stitching the seam.
 6. A self-supporting earth facing module according to claim 1, wherein the sheet material is a single, rectangular piece of polymeric geogrid material with a width approximately equal to the extension length of the assembled module.
 7. A self-supporting earth facing module according to claim 1, wherein the geogrid sheet material has an overall sheet length equal to about 10 to 15 times the diameter of the tubular sock.
 8. A self-supporting earth facing module according to claim 1, wherein the tubular sock is formed in modular sock units that are connected in line serially to form a sock facing row.
 9. A self-supporting earth facing module according to claim 8, wherein each modular sock unit has a built-in drip irrigation tubing with male/female interconnection ends that can be connected serially end-to-end for a continuous row of facing with irrigation support for each horizontal earth layer.
 10. A self-supporting earth facing module according to claim 1, adapted for durable applications, wherein the geogrid sheet material is made of high-tenacity knitted polyester yarns with high molecular weight and covered with a polymeric coating.
 11. A self-supporting earth facing module according to claim 1, adapted for environmentally sensitive applications, wherein the tubular sock of the module is made of natural and biodegradable fabric material, such as a coir blanket woven from coir twines made of bristle coir obtained from freshwater cured coconut husks.
 12. A method of construction of a mechanically stabilized earth (MSE) wall or slope comprising the steps of: (a) providing a plurality of self-supporting earth facing modules, each comprising a tubular sock made of a selected fabric material having a hollow interior volume which is to be filled with a compost or fill material so as to form a semi-rigid sock facing, and a geogrid sheet made of a geosynthetic sheet material which extends around the circumference of the tubular sock with upper and lower extensions extending in a horizontal direction of the module to one side of the tubular sock, wherein the sheet material of the geogrid sheet is joined by a high-strength seam to the sock material at a juncture point of at least the lower extension of the geogrid sheet with a circumferential point of the tubular sock, (b) placing a first row of one or more modules of tubular sock facing on a gravel leveling pad along a prescribed wall alignment, with the lower geogrid sheet extension of each module pulled out flat on top of the gravel pad, and with the upper geogrid sheet extension laid loosely back over the module in the opposite direction, and where the end of each module adjoins an adjacent module, overlapping the excess lower geogrid sheet extension onto the lower geogrid sheet extension of the adjacent module after first spreading a thin layer of granular fill onto that lower geogrid sheet extension to prevent the two geogrid sheet extensions from being in direct contact with each other; (c) with the row of tubular sock facing in place, filling granular backfill on top of the lower geogrid sheet extension of each module of tubular sock facing to provide a vertical lift as high as the module height, and compacting the lift of backfill material to form a reinforced zone; (d) pulling the upper geogrid sheet extension of each module of the row of tubular sock facing back over the module and laying it flat on top of the compacted backfill lift, then spreading a thin layer of granular fill across the top of each upper geogrid sheet extension; and (e) placing a next row of one or more modules of tubular sock facing on and slightly offset behind the first row of tubular sock facing to form a sloping set-back in the wall face, and repeating steps (a) to (d) to form a next vertical lift of tubular sock facing; and (f) repeating step (e) for placing each next row of tubular sock facing for the next vertical lift until a desired height of the facing wall is reached.
 13. A method for construction of an MSE wall or slope according to claim 12, adapted for forming a vegetative facing wall, wherein the tubular sock of each module is pre-seeded or hydroseeded and provided with irrigation support to form a vegetated MSE wall or slope.
 14. A method for construction of an MSE wall or slope according to claim 12, adapted for durable applications, wherein the geogrid sheet material is made of high-tenacity knitted polyester yarns with high molecular weight and covered with a polymeric coating.
 15. A method for construction of an MSE wall or slope according to claim 12, adapted for environmentally sensitive applications, wherein the tubular sock of each module is made of natural and biodegradable fabric material, such as a coir blanket woven from coir twines made of bristle coir obtained from freshwater cured coconut husks.
 16. A method for construction of an MSE wall or slope according to claim 12, adapted for forming a vegetative facing wall, wherein live vegetation in the form of sprigs or live cuttings are inserted between lifts.
 17. A method for construction of an MSE wall or slope according to claim 12, wherein the rows of tubular sock facing are laid to form a curved wall having one of (a) a concave shape with the geogrid sheet extensions being cut perpendicular to the axis of the tubular modules to allow spreading of the geogrid sheet extensions to form concave curves, and (b) a convex shape with the geogrid sheet extensions being cut perpendicular to the axis of the tubular modules to allow overlapping of the geogrid sheet extensions to form convex curves.
 18. A method for construction of an MSE wall or slope according to claim 12, wherein to assure optimal granular interlock between the backfill and the geogrid sheet extensions, the backfill material consists of granular, well-graded sand or sandy gravel with less than 15 percent by weight passing the No. 200 sieve, and with a maximum particle size of 0.75 inch (19 mm).
 19. A method for construction of an MSE wall or slope according to claim 12, wherein the extension length of the geogrid sheet extensions in a granular interlock zone behind the facing modules is at least twice the diameter of the tubular sock modules.
 20. A method for construction of an MSE wall or slope according to claim 12, wherein a tall wall is constructed using supplemental geogrid extensions to widen the geosynthetic stabilized earth zone with the supplemental geogrid extensions being sandwiched in-between the geogrid extensions of the tubular sock facing modules. 